CSR 2013

fostergamko

REPORT

2013

working today, protecting tomorrow

REPORT

R


Corporate Social Responsibility Report 2013

Contents

working today,

protecting tomorrow

About Foster 4

Our philosophy 5

Climate Change

EcoPro G2 6

Refrigerants 10

Zero gas leaks 11

Coldrooms 12

Energy saving innovations 14

Carbon footprint 16

Our manufacturing facility 18

Measuring our progress 20

Product miles 21

Sustainability

Reducing our impact 22

Built to last 23

Recycling 24

Waste management 26

New fibre laser 28

Social

Responsibility

Independent

Verification

Summary

Taking the industry lead 30

Being global, acting local 31

Responsible sourcing 32

Health, safety and welfare 34

Our people 35

Independent verification 36

BREEAM 38

Awards 39

Achievements and future plans 40

About this report 43

2


‘‘Working today, protecting

tomorrow is still our mandate.’’

Welcome to our second Corporate Social Responsibility report.

This publication is about the progress we have made since our first report on the key

areas of climate change, sustainability and social responsibility. The credibility of the

data we publish remains an important factor in support of our leadership in these

areas so we have continued to use independent bodies to audit and verify

our information.

Many new initiatives and plans have been included in this report which underline our

enthusiasm and commitment in creating a sustainable future for our employees, our

customers and our community.

Our first CSR was entitled ‘working today, protecting tomorrow’ and this

is still our mandate. We are proud of our achievements so far and are

dedicated to working towards a more sustainable environment and

maintaining our position as environmental leaders.

Paul Veried

Vice President Refrigeration

& Weigh Europe

3


Corporate Social Responsibility Report 2013

About Foster

Foster Refrigerator is the UK’s premier commercial

refrigeration manufacturer, with a market

leading position in the UK and a rapidly expanding

international business.

Foster sells a wide range of award-winning

refrigeration equipment and systems

into diverse end user markets such as

restaurants, pubs, hotels, fast food outlets,

staff catering and supermarkets, and in

the public sector to schools, universities,

hospitals, Ministry of Defence and Social

Services. The innovative product range

includes refrigerated storage cabinets and

counters, under counters, blast chillers and

freezers, prep stations, walk-in coldrooms,

multidecks, refrigeration systems, bakery

refrigeration, ice makers, water coolers and

temperature monitoring.

Foster is at the forefront of new technology,

pioneering new standards in temperature

control, hygiene and efficiency.

Premium products, together with our

support services, enable us to maintain

long-term relationships with our partners.

Foster views environmental management

as an integral component of our overall

business decision-making, and strives to

achieve environmental best practice in all of

our manufacturing and supply operations.

We are committed to developing and

marketing products which have excellent

environmental characteristics, and which

meet current best practice.

Foster Refrigerator’s parent company, ITW,

is a leading Fortune 150 manufacturer

of a diversified range of value-adding

industrial products and equipment. ITW’s

Food Equipment business, of which Foster

is part, is the No.1 global manufacturer of

food equipment and includes other market

leading brands such as Hobart, Traulsen,

Bonnet, Thirode, Gamko, Avery Berkel, Wolf,

Vulcan and Colged.

4


1.0 Climate change

Our philosophy

Climate Change

Reducing our carbon footprint and

designing products with the lowest

possible environmental impact.

Social Responsibility

Providing business leadership in ethical

standards, local supply, community

support and a safe working environment.

Sustainability

Reducing, reusing and recycling our

waste and setting yearly reduction

targets.

Independent

Verification

Environmental leadership verified by

independent test authorities and

industry recognised audit bodies.

5


Corporate Social Responsibility Report 2013

1.0 Climate Change

Foster took two significant green steps during 2011 and 2012,

both of which were major landmarks in the company's history.

The first of these was the major investment of over £4m in a

low carbon production facility, and the second was the design

and launch of the ultra low energy EcoPro G2 range, the first

all-new product to run off the new production facility.

Key climate change achievements

2005

ECA Listing

Foster Refrigerator becomes

the first in its industry to be

listed on the governments

Energy Technology List

2009

Carbon Trust Standard

Foster Refrigerator becomes

the first refrigeration

manufacturer to be awarded

the Carbon Trust Standard for

its low carbon manufacturing

2006

Low Energy Range

Foster Refrigerator launches

its low Energy Eco Pro range

2012

EcoPro G2

After a £4 million factory

investment Foster

Refrigerator launches the

brand new ultra low energy

G2 range

6


1.0 Climate change

“Designing the new G2 from

scratch gave our engineering team

a chance to assess and minimise

the environmental impact of every

component and function.

We are very proud of the result”

Chris Playford | Market & Development Director

See how far the G2 has evolved in terms of energy

reduction compared to previous Foster models:

Foster Range

Foster model

Proline

PROG600H

Eco Pro

EPROG600H

EcoPro G2

EP700H

Carbon savings

In the first 12 months the

combined energy saved by

the new G2 compared to

our first Proline Cabinet is

the equivalent to 307 acres

of forest preserved from

deforestation.

Lighter use

of energy

The EcoPro G2 Range

has set new standards in

low carbon refrigeration.

The popular 600 litre

refrigerator uses less

energy than a traditional

light bulb.

Date

2008

2009

2012

Energy use (kWh/48h)

9.4

3.7

2.99

*Annual running cost

£205

£81

£65

**KgCO2e per annum

899

354

286

*Running Costs based on 12p kWh.

**Using the Carbon Trust's current figures of 0.5246 kWh to KgCO2e for electricity.

7


Corporate Social Responsibility Report 2013

The EcoPro G2

Independent laboratory tests on the

G2 cabinet clearly demonstrated the

product's world-beating energy-saving

performance and enhanced Foster's

clear lead in this field.

We also asked hundreds of our customers to energy

test their G2 cabinets in their own kitchens.

Foster provided complimentary energy monitors

and the products were tested during day to day

kitchen activities.

“The energy testing process really

brought home to me just how much

energy can be saved by using Foster.

The average energy usage on the G2

fridge was only 90p per week – that’s

just 13p per day. They’re savings you

just have to sit up and take notice

of, especially when applied to multiple

products across multiple sites.”

Lynda Mitchell | Commissioning & Contracts Manager, North Somerset.

Independent laboratory tests

show the cost to run an

EcoPro G2 EP700H annually is

£65.30

20% more

efficient when tested in

a real world environment

The remarkable results showed that in real world

tests the EcoPro G2 was a further 20% more

efficient than the independent laboratory tests

conducted by RD&T.

Foster

G2 EP700 H

Education

Healthcare

Government

Restaurants

Hotels

Foster G2

EP700 H

real world annual

average tests

@ 12p per kWh

£55.40

£44.45

£50.40

£49.88

£60.48

Foster G2

EP700 H

independent

laboratory test

annual average

£65.30

Average

£52.12

Results received from data submitted independently by customers

and has not been verified by a third party. Data obtained by using

standard off the shelf energy monitors (product code N47KB)

8


1.0 Climate change

Key low energy designs of the new G2

Our most technically advanced and energy efficient model yet.

NEW

Cabinet design

NEW

Refrigeration

More robust cabinet design with market

leading storage capacity provides

exceptional customer value.

Brand new refrigeration system designed

to be the most technologically advanced

and energy efficient yet.

NEW

Evaporators

NEW

Ventilation

Twin circuits ensure the evaporator is

providing effective cooling throughout the

whole of the evaporator coil maximising

cooling performance.

New ‘Airlines’ grill provides effective

ventilation that cools the compressor

which reduces running time by 15%.

ISO Climate Class 5

Foster equipment works efficiently and

most importantly maintains temperature

in the hottest and toughest of kitchens.

NEW

Insulation

Cyclopentane foam insulation improves

thermal efficiency.

NEW

Door interface

The new door is rebated to the rear,

providing a ‘cold’ barrier that protects

the door seal and reduces energy

consumption.

NEW

Food Fresh

Dynamics

Fluid Food Fresh Dynamics modelling

improves air distribution which optimises

performance and reduces energy -

keeping food fresher for longer.

NEW

Controller

Smart electronics (e-mode/energy),

deliver even closer energy control

reducing consumption.

9


Corporate Social Responsibility Report 2013

Refrigerants

We are proud of our record in pioneering the use of

new greener refrigerants in commercial refrigeration

- refrigerant performance and environmental

sustainability is an ongoing priority.

Our first CSR report dealt in detail with

our pioneering work with Hydrocarbon

refrigerants. Foster was the first company

to introduce Hydrocarbon refrigerants into

commercial refrigeration equipment in

Europe and we continue to be the prime

supporters of the gas in our industry.

Zero gas leak strategy

New refrigerants such as hydrocarbon have

a much reduced global warming potential

but loss of refrigerant from a system also

has a significant impact on climate change

through the resulting increase in energy

usage. Although factory-made refrigeration

systems have a much lower leakage rate

than split systems assembled on site,

building robust sealed units to minimise

any potential gas leak is important in

saving energy costs.

Foster’s ‘Zero Leak Strategy’ objective is to

eliminate gas leaks and we have invested

heavily in the latest and best technology

available to help us achieve that.

Foster was the first to standardise

Hydrocarbon refrigerant in public

sector cabinets

Use of Hydrocarbons

at Foster

42%

29%

5%

2005

2009

2011

The effect of refrigerant leakage

on refrigeration performance and

energy consumption from the

Carbon Trust

Costs (£)

Operator's business

is now affected

1 2 3 4 5 6 7 8 9 10

Time

Leak starts

Refrigerant loss starts

to affect performance

Consequential losses

Additional energy costs

Repair costs

Refrigerant loss

System can no longer

support cooling load

“If a refrigerant leak is not

promptly repaired it will start

to effect system efficiency

and the energy cost for

the refrigeration system

will increase. Eventually the

refrigeration system will no

longer be able to provide enough

cooling which could lead to

product or other losses.

The longer you leave the leak

before repairing it, the higher

the cost for the repairs,

refrigerant loss, additional

energy usage and other

consequential losses”

Carbon Trust

10


All products are subjected

to three separate tests to

ensure there are no leaks:

1. Vacuum testing the system

The refrigeration system is pulled down

to generate a vacuum that is held for

a period of time, any leaks at this stage

are identified by a reduction in the

vacuum.

2. Helium gas testing

The system is then tested using helium

gas to find any miniscule leaks. Why

are we using helium gas? The molecules

in Helium gas are the second smallest

molecule size possible, excellent for

finding the smallest of gaps and our

detecting equipment can measure this.

3. Conventional leak detection tests

are undertaken after the system

is charged with refrigerant

A final check is made after the system

is charged with refrigerant.

Foster uses quality

components in our

refrigeration system

Examples include:

> Highly corrosion resistant cataphoresis

coated evaporators - the evaporator in

the refrigeration system is coated with

a unique membrane which makes it anti

corrosive.

> Computerised copper pipe bending -

allows pipes to be bent without any

distortion or deterioration in integrity

of the refrigeration system.

11


Corporate Social Responsibility Report 2013

Coldrooms

Making better use of what you have is a

sound sustainable principle. Foster Coldstores

have solved clients needs for more storage

capacity not by extending or building new

coldrooms but by redesigning the storage

within their existing rooms. This is not only

cost effective but also means a significant

saving in energy needed for customers

increased storage demands and a reduced

carbon footprint.

J.D.Wetherspoon’s dual compartment

room (right) had storage capacity of

15.25 M 2 . Redesigning the shelving

increased this to 21.04 M 2 increasing the

walk-ins storage space by 38%. A very cost

effective and environmental solution.

38%

increase in storage

space using clever

interior design

12


1.0 Climate change

“Bad coldroom layouts often mean unusable

spaces are refrigerated, wasting energy

and floor area. Good coldroom design saves

money and the environment.”

Brian McDermott | Director Foster Coldstores

Original coldroom

NEW coldroom layout

Case study

Energy saving

coldroom design

Our innovative coldroom design has

significantly reduced the carbon footprint

of Greggs’ new bakery in Norwich. The new

Foster Eco Star refrigeration system delivered

an energy saving in excess of 30%.

This system differs from traditional

equipment as it is designed to precisely

match the required load at any given

time and consequently to reduce energy

consumption. For example, overnight when

everything is down to temperature, the unit

slows and saves electricity while a traditional

unit will cut in and out at full speed and

uses far more energy. If in the future Greggs

wishes to increase the size of the coldroom

(within certain limits) this can be achieved

using the existing Eco Star refrigeration

unit with an increased running speed -

a benefit that saves both the cost and

the environmental impact of installing

an additional refrigeration system.

30%

energy saving over installing

3 standard condensing units.

The Octagon Varispeed is an inverter driven

condensing unit. It has the ability to match

the required refrigeration duty. Motors

usually operate on 50Hz but this is capable

of operating between 30 and 87Hz to

meet demand.

13


Corporate Social Responsibility Report 2013

Energy saving innovations

At Foster we operate all our manufacturing plants

using advanced ITW and Lean Manufacturing

techniques and processes.

The benefits of this approach are not only reflected in one of the most

advanced commercial refrigeration plants in Europe but also in lower

operational costs, improved quality, enhanced productivity, reduced

waste and greater energy savings.

Many of the ITW and Lean

Manufacturing techniques have

contributed either directly or indirectly

to helping us reduce our energy

consumption and our carbon footprint.

Some examples include;

> Lights out manufacturingour

investment in the latest laser

machines means that operations

can continue through the night.

> Improved product testing -

all Foster products are 100%

tested before leaving the factory.

New and innovative techniques

for completing these tests have

reduced energy consumption

during the process by 70%.

> Lean supply chain and a ‘maketo-order’

environment has helped to

reduce material stocks which in turn

has reduced damage, waste and the

space required to store it all by 34%.

Thereby reducing the lighting and

heating by the same percentage.

> Our distribution partner is based within

a few metres of our production

lines. Foster products are therefore

only handled once, are not required

to travel great distances to the

warehouse and can be produced in

line with customer demand. This

reduces damage, the need for

extensive and costly warehousing

and reduces our carbon footprint.

70%

less energy usage than

traditional ‘test methods’

due to more accurate and

precise test times

14


1.0 Climate change

Insulation

Foster has adopted cyclopentane

insulation as a major new step

in increasing the sustainability of

our products.

High performance cyclopentane

foam is more thermally efficient

than traditional foams and maintains

performance of the product for longer.

Global Warming Potential (GWP) 6*

(*Appropriate value for comparison,

R134a blown foam has a GWP of 1430)

13%

improvement in efficiency

by using Cyclopentane

15


Corporate Social Responsibility Report 2013

Carbon footprint

Foster is the first in the commercial refrigeration

industry to achieve recertification of the Carbon Trust

Standard. We continue our leading industry-position

having been the only company in our sector to achieve

the Standard in 2010.

Foster has set a carbon reduction target of 2.5% year

on year. This has been achieved and exceeded through

our investment in new plant and products and by our

continuous improvement processes throughout

the company.

The 2012 recertification monitored the

carbon footprint of all Foster’s operations

including service and transport. During

the recertification period (2009 to 2011)

the Carbon Trust certified that Foster has

improved its carbon efficiency by 14%

relative to the output of cabinets sold. This

greatly exceeded the 2.5% per year target.

Foster is proud that it has significantly

reduced its environmental impact.

However sustainability remains a priority

and with the Carbon Trust Standard

certificate being valid for just two years,

Foster is committed to working even harder

to reduce carbon emissions and continue

to be a Carbon Trust Standard Bearer.

We improved our

carbon efficiency by

14%

(2009-2011 assessment period*)

*tonnes CO2e/cabinets

16


1.0 Climate change

The Carbon Trust Standard

To achieve the Carbon Trust Standard, organisations

must firstly measure their direct carbon footprint

(comprising emissions generated from onsite

fuel and electricity use, for example), then prove

that good carbon management practices are in

place, and demonstrate genuine reduction in their

emissions over a two year period.

17


Corporate Social Responsibility Report 2013

Our manufacturing facility

We have invested millions of pounds in our

manufacturing facilities to not only ensure

world class standards of efficiency and quality

but also to drive continual reductions in our

carbon footprint.

EcoPro G2 Low Carbon Production Line

6

Packaging

changed to

eliminate

propane

heaters

5

New

footprint

cabinet

testing

method

4

New foaming

equipment uses

less energy than

previous

machines

3

Improved

assembly process

saves energy

2

Kanban system

for sheet metal

parts from laser

eliminates paper

systems

1

Low energy fibre

optic laser cutter

uses 60% less

energy than a

standard laser

SINGLE SECTION MODELS

DOUBLE SECTION MODELS

6 5

REFRIGERATION AND CABINET ASSEMBLY

FINISHED CABINETS

FINISHED CABINETS

REFRIGERATION AND CABINET ASSEMBLY

11

10

4

9

SHELL

FOAMING

3

8

SINGLE

SECTION

SHELL

ASSEMBLY

12

DOUBLE

SECTION

SHELL

ASSEMBLY

2

SHEET

METAL

KANBAN

SYSTEM

1

7

FIBRE

OPTIC

LASER

NITROGEN

GENERATING

PLANT

SHEET METAL FACTORY

12

Reusable plastic

containers

eliminate

cardboard waste

11

Brazing gas now

on ring main

eliminating gas

bottles and

wastage

10

LED lighting

installed

throughout the

plant giving a 70%

energy saving

9

New foam and

blending equipment

significantly reduces

waste

8

New build fixtures

reduce

compressed air

generation and

usage

7

On site nitrogen

generation. No gas

deliveries, good for

the environment

18


1.0 Climate change

Proud to hold both the

ISO9001 and ISO14001

quality and environmental

marks

70%

Energy saving by using

LED lighting in the office

and factory

£4m

invested in our

manufacturing facility

for the G2 range

19


Corporate Social Responsibility Report 2012 2013

Measuring our progress

One of our key environmental measures is to

understand our progress in lowering our carbon

footprint by measuring the amount of energy

it takes to produce a product. This is a simple

but effective measure that removes demand

fluctuations and clearly shows the energy

used per product produced.

Gas usage kWh per cabinet produced

2008

2009

2010

2011

Carbon

offsetting

Foster calculated the CO2

emissions of our paper usage

in the year 2010/11 to be the

equivalent of twelve trees.

We partnered with a local

school and provided trees

for the children to plant.

89 82

Electricity usage kWh per cabinet produced

75

65

We encourage our staff to

reduce their paper usage

and what we use from now

on we will offset on an

annual basis.

2008

2009

2010

2011

114 114 106 101

IT energy saving

Investment in modern server

technology has delivered a

35% energy saving.

30%

reduction

in desktop

power use

due to a new virtual

desktop infrastructure

20


1.0 Climate change

Product miles

As a British manufacturer the distance your product travels

from the factory to a UK customer creates significantly less

carbon emissions than an imported product.

Fosters journey for product to customer

> >

Importers typical journey for product to customer

> > > > > > > >

Fleet emissions

CO2 emissions per cabinet produced

18.0kgCO2

2007

16.2kgCO2

2008

15.1kgCO2

9.1kgCO2

2010

2009

64%

reduction in C02 over

five years

6.6kgCO2

2011

21


Corporate Social Responsibility Report 2013

2.0 Sustainability

Reducing our environmental impact

The worlds resources are finite so we have to

ensure that we do as much as we can to reduce the

use of those resources and think about the impact

on our future generations.

At Foster we are committed to

operating the business in a

sustainable way for the benefit

of future generations and we put

sustainability at the centre of our

environmental approach.

Our sustainable responsibilities fall

into two simple categories:

> Making products that are long

lasting and recyclable.

> Sustainable manufacturing.

Key sustainability achievements

2005

ISO 14001

Foster became the first

in its industry to gain

the Environmental

Management Standard

2008

International Green Award

Foster wins Food Service

Consultants International

Green Award

2006

Recycling

Foster implements a 98%

recycling process for end of

life products

2012

EcoPro G2

G2 wins Cooling Industry

Award for innovation,

performance and

sustainability

22


2.0 Sustainability

Making products that are

long lasting and recyclable

Delaying the environmental impact of

making a new product.

Built to last:

> Low energy fan motors

are considerably more efficient and

generate a fraction of the heat of

conventional fan motors, lasting up

to four times longer.

> Hydrocarbon refrigerant

has lower Global Warming

Potential (GWP) and is kinder

to the environment.

> ISO climate class 5 rated system

designed to maintain temperature

in even the most demanding of

kitchens.

> Heavy duty hinges and door fittings

tested to 250,000 openings

equivalent to 100 openings per

day for 7 years.

> Heavy duty castors

rated to 100kg per castor, that’s

400kg per cabinet.

> Increased insulation thickness

improves the thermal efficiency

of the cabinet, less heat is able to

pass into the cabinet interior so

less energy is required to keep the

cabinet cold.

Built to last

robust construction

with advanced thermal

efficiencies

> Cataphoresis coated coils

provide superior corrosion

resistance in comparison to

standard coils.

> Robust shelving

rated to handle 40kg per shelf

loading as standard.

5 steps

Foster endorses

the 5 step waste

management hierarchy

Reduce, Reuse, Recycle,

Recover, Landfill

most favoured option

least favoured option

Reduce

Lowering the amount of waste produced...

Reuse

Using materials repeatedly...

Recycle

Using materials to make new products...

Recover

Recovering energy from waste...

Landfilll

Safe disposal of waste through landfill.

23


Corporate Social Responsibility Report 2013

Recycling

At the end of their useful lives

Foster ensures that up to 98%

of the old products are recycled

or reused.

> Non ferrous and copper

melted and reused

> Microprocessor processed

and reused

> Refrigerant made inert

> Compressor oil into green

energy

> Plastics processed into

garden tools

> Ferrous metals melted

and reused

> Insulation processed into

green energy

24


2.0 Sustainability

Foster recycling process

In these crucial economic and environmental times,

it has never been more important to recycle.

Protecting the environment, minimising pollution

and reusing as much as possible.

Arrival of

product &

inspection

1>

Parts removed

sent to

re-processors.

All re-processors

licensed by

Environment

Agency as

Treatment Facilities

(AATF)

Removal of parts:

shelving/castors/

microprocessors

2> 3>

Removal of

compressor

4

Remainder of

the product is

crushed

Crushed product

placed in sealed

chamber filled

with nitrogen

gas. The product

is then shredded

into small pieces

Refrigeration

system de-gassed

& oil removed into

separators

>

5

>

6

>

Refrigerant

gas placed in

pressurised

containers.

High temperature

incineration

converts to

harmless salts

Empty

compressors sent to

re-processing

metal plants

Gas is removed &

rapidly cooled in

liquid nitrogen, this

turns the removed

gas into a liquid.

It is stored

in pressurised

containers and

re-processed

Compressor oil is

reclaimed & sent to

Energy from Waste

(EfW) – a process

which recovers

energy from waste

materials in a

controlled &

regulated

environment. This is

supplied to the National

Grid to support ‘Green’

electricity

Foam pellets are

produced &

recycled into plastic

plate manufacture,

oil spill absorbents or

used in Energy from

Waste (EfW)

7>

8>

9>

10 Plastics

separated

out & sent to

re-processor

A magnetic

separator

collects all

the ferrous

metals

An Eddy

Current

separator

collects all

the non

ferrous metals

(aluminium,

copper etc)

Polyurethane foam

is treated with heat

& mechanical

pressure (still under

inert conditions) to

release more of the

CFC/HCFC/HFC gas

Plastic is

recycled into

horticultural

products

25


Corporate Social Responsibility Report 2013

Waste management

Our lean manufacturing techniques and ISO14001 environmental

management system have been the cornerstones in controlling and reducing

waste in our manufacturing process. The efficiencies of lean manufacturing

naturally reduce waste and the discipline of ISO14001 ensures that we

analyse the environmental impact of our waste in order to reduce or

eliminate it wherever possible.

General waste

This includes waste such as plastics and

polystyrenes. This has been reduced by

72% since 2009.

Brazing gas

The gas for brazing on the new

production lines is now on a ring main

eliminating the need for multiple gas

bottles and saving on the amount of

gas used.

Warehouse space

Manufacturing has reduced the

need for space by 34%, saving on

energy, materials and equipment.

Paper waste

Using the Kanban paperless system

in production saves 50,000 sheets of

paper a year.

Chemical waste

We have introduced a new

cyclopentane mixing system

which greatly reduced the

amount of chemical waste

from the foaming process.

Cardboard waste

Foster has reduced cardboard

waste in manufacturing by

introducing reusable plastic

containers. These are used by

our suppliers and throughout

the plant.

82%

chemical waste reduction

since 2005

26


2.0 Sustainability

Wood waste

Foster waste per annum

Wood waste has been reduced by 25% since 2011 and 100% of our wood waste

goes to composting and is fully recycled. Composting is the degradation or the

breaking down of organic materials. This process is speeded up by reducing the size

of the materials, mixing, correct moisture and air content which allows the microbes

to convert the material to compost. Our process for recycling wood waste is

shown below: 56%

Reduction

1>

The waste is brought to site &

weighed in on a weighbridge.

2>

3>

The material is loaded into an

Ecopod system that completely

encases the composting materials.

The composting materials are kept

aerated for ten weeks.

The material is then shredded

& sorted. Any non - compostable

materials, such as plastic bags,

litter etc are removed.

4>

The Ecopods are carefully monitored

to ensure the correct temperature &

air flow is maintained throughout the

composting process.

Cardboard waste (kg/cab)

2012

0.65

2011

0.83

2010

1.06

2009

1. 47

General waste (kg/cab)

72%

Reduction

2012

3.06

2011

3.42

2010

3.84

2009

4.25

Metal waste (kg/cab)

5>

The compost is then matured in

heaps for three to nine months

before being screened and graded

to the PAS100 standard.

Usage of

Recycled Compost

0-40mm which is used in

agriculture

0-25mm which is used as a soil

conditioner often used in landscaping

31%

Increase

2012

13.66 *

2011

10. 41

2010

11.69

2009

11.60

0-10mm which is used as a

top dressing grade in

horticulture

* Includes plant refurbishment waste

of redundant fixtures and fittings.

Foster expects this to reduce in 2013

and resume its downward trend.

27


Corporate Social Responsibility Report 2013

Improving our sustainability

in manufacturing

New fibre laser

Foster has invested in the very latest laser

technology to dramatically reduce power

consumption, improve component accuracy

and reduce waste. In a traditional CO2 type

laser, light is generated by electronically

exciting CO2 molecules. This process is costly

and inefficient as a large amount of energy

is wasted as heat.

The Diode Pumped Laser (fibre optic)

features a fibre laser module that requires

much less power and provides quicker and

more accurate cutting. Additionally, gases

such as carbon dioxide and helium are not

required in the process.

Much improved reliability and life span also

contribute to its sustainability credentials.

Laser

Comparison

C0 2 Laser

3000W

Fibre Laser

3000W

Power Consumption 55 kW 14 kW

Chiller Consumption 32 kW 11 kW

71%

energy saved by

adopting fibre optic

laser technology which

improves processing

efficiencies

28


2.0 Sustainability

29


Corporate Social Responsibility Report 2013

3.0 Social responsibility

Taking the industry lead

As a division of ITW a Fortune 150 Corporation,

Foster is committed to the highest standards in

business practise and we continue to strive to

maintain our leadership role in this important area.

Whether it’s working closely with our

local community, developing a local

supplier base, investing in our

employees, meeting the standards of the

Ethical Trading Initiative or developing

our membership of SEDEX,

we demonstrate our commitment to

social responsibility through our actions

and achievements.

Key social responsibility achievements

2005

Code of Ethics

All Foster employees

adopt ITWs code of

ethics and practices

2010

Ethical Trading

Foster signs up to

ETI base code

2009

CSR Report

The first Corporate Social

Responsibility Report in the

industry.

2011

Investing in People

Foster wins national skills

and training award from

Engineering Employers

Federation

30


3.0 Social Responsibility

Being global, acting local

We work closely with the local communities in which

we operate. We sponsor local events and charities

and collaborate with local schools and businesses.

In the UK a team of 36 Foster staff and

customers took part in the famous Three

Peaks Challenge, walking the highest

mountains in Scotland, England and Wales

within 24 hours.

The challenge required the team to cover

1300 road miles as it moved around the

country to undertake a combined 32 mile

hike scaling Mount Snowdon, Scafell Pike

and Ben Nevis, an achievement which

should in no way be underestimated.

Through their efforts £2393 was raised for

COCO (Comrades of Children Overseas),

which is a children’s charity that aims to

improve the lives of children living in poverty

in the developing world through health and

education initiatives, and £9,635 was raised

for the Multiple Sclerosis Society, a cause

which funds research into a disease which

affects 100,000 people in the UK.

Every year Foster organises a green week

where employees are encouraged to

get involved. A highlight of this year was

organising an art competition in

conjunction with local school Ashwicken

Junior.

The themes were:

Year 1: sea pollution, litter and oil spills

Year 2: caring for our environment,

animals and woodland

Year 3: deforestation and saving the

rain forest

Certificates and prizes were presented

to each group by Ashley Sword, Foster's

Sales Director.

Foster Green Week

Three Peaks Challenge

31


Corporate Social Responsibility Report 2013

Responsible sourcing

We try to source our components locally where

possible to support local businesses but also to

ensure that product miles remain low. This applies

for every country in which we operate.

Where local sourcing is not possible we

aim to ensure through the Ethical Trading

Initiative (ETI) and SEDEX standards

that our sourcing is in line with our social

responsibility targets.

ETI is an alliance of companies, trade

and voluntary organisations working in

partnership to ensure that the lives of

workers are improved worldwide.

Foster Refrigerator is working towards

meeting the requirements of the ETI

Base Code along with a number of

other leading UK companies.

51%

of these are within

a 35 mile radius of

our UK factory.

As part of this drive in our business,

the Base Code of Ethical Purchasing

is designed to promote safe and fair

working conditions, and the responsible

management of environmental and social

issues in Foster Refrigerator’s Supply Chain.

This Code clearly sets out the standards

we wish to achieve for our business with

the help of our suppliers over time. These

standards are not bureaucratic, they simply

ensure business is conducted without

exploitation or abuse.

The principle of continuous improvement

applies to all aspects of the Code and we

will work collaboratively with our suppliers

on the implementation of the Code. This

will involve audits and site visits to assess

suppliers’ performance against the Code in

the spirit of improvement and compliance

to the code.

32


3.0 Social Responsibility

Sedex membership

85%

of our suppliers

are UK based

In addition to ETI, Foster is also a

member of SEDEX which is the

largest collaborative platform for

sharing ethical supply chain data.

Since 2004 over 25,000 organisations

from around the world have made

SEDEX their platform of choice for

exchanging ethical supply chain data.

SEDEX is a not for profit organisation dedicated to driving

ethical improvements in global supply chains. It provides a

secure online platform for sharing and viewing information

on labour standards, health and safety, the environment

and business ethics.

KINGS LYNN

33


Corporate Social Responsibility Report 2013

Health, safety and welfare

Foster is very proud of our health and safety record

and the well-being of employees is an important part

of our social responsibility approach.

The Foster business continues with

promoting a strong culture of 'Heath and

Safety' and 'Welfare at Work' for all our

employees. The company occupational

health scheme is backed by a strong focus

on health and safety at work. Fosters'

record on health and safety is exemplary

and reflects the level of engagement on

these issues from the entire organisation.

Our focus on health and safety extends

outside the organisation and Foster is a

member of the Safe Contractors Scheme

which is one of the fastest growing health

and safety accreditation programs in the

UK. We are also a member of the Altius

(Assured Vendor Scheme).

Number of incidents

3

2.5

2

1.5

1

0.5

0

Accidents/incidents per every

10,000 hours worked

2009

2010

Year

2011

2012

Foster records even the most minor

incidents in our accident records

and these are included in the above

figures

40%

reduction in

accidents since

2009

34


3.0 Social Responsibility

Our people

Key to Foster's role in the local community is

that of employment, where we have given

employment to local people for over 40 years.

We are proud of our working environment, our commitment to our people and

our business ethics. Foster is an equal opportunities employer, with a strong

reputation in the community. We offer very competitive salaries and benefit

packages, which enables us to attract and retain staff of the highest calibre.

We also have very low staff turnover rates averaging just 2% per year.

Training

Foster believes in placing strong

investment in developing our people.

Our focus on training is about giving

our employees the confidence,

empowerment and skills to drive our

culture and business forward.

Every new starter at Foster

undertakes a two day induction that

includes a recognised CIEH Level 1

award in Health and Safety in the

Workplace.

All our full time employees are

trained to NVQ level 2 in Lean

Manufacturing techniques. Foster

also supports staff wishing to

undertake MBAs, and other

professional qualifications.

We are proud to have been

recognised nationally for our training

as regional winner and national

runner up by the Engineering

Employers Federation for the 2011

Skills & Training Award.

35


Corporate Social Responsibility Report 2013

4.0 Independent verification

Independent verification is the only true way to determine

the real environmental benefits of a product

There is a wealth of environmental data

and performance claims for products

in the market place today. Any buyer

needs to have the confidence that a

product will truly perform as it has been

described, and the only way to ensure

this is to be sure that the information

supplied has been independently checked

and verified. Foster ensures that all key

performance and environmental data

relating to our products, our company and

the information in this report has been

independently scrutinised. The history

time line (right) shows that this has been

our company’s culture for many years.

Foster’s reputation and knowledge is also

being used to shape future environmental

legislation in our market sector. We are

involved with the European Commission

on the EuP programme creating the

successor to the current ETL method of

measuring energy performance with a

new mandatory standard similar to energy

labelling on domestic products.

By Appointment to

Her Majesty Queen Elizabeth II

Suppliers of Commercial Refrigeration

Foster Refrigerator, King’s Lynn

> Our two ISO standards ISO 9001 Quality

Management Standard and ISO14001

Environmental Management Standard

are audited by Lloyds Register Quality

Assurance (LRQA) with 6 monthly

surveillance visits and full triennial

reassessments every three years.

> The Enhanced Capital Allowance

Scheme (ECA) enables private sector

buyers to claim tax concessions on

low energy products. Products qualify

if they are listed on the government’s

Energy Technology List (ETL). Data

for this can be by self assessment or

independent verification. Although

many suppliers choose the self

assessment route Foster’s data is

independently assessed.

> Our products’ energy performance is

tested by RD&T an independent test

body (originally Bristol University) the top

test house in the country for commercial

refrigeration.

> The sustainability performance of

our manufacturing plant is evaluated

by the Carbon Trust a not for profit

organisation that measures and

certifies environmental footprints of

organisations, products and services.

Foster is very proud to be the first and

only company in our industry to achieve

the Carbon Trust Standard and to gain

biannual recertification.

We don’t accept ‘green wash’.

It is easy to claim environmental

leadership but not easy to prove.

All our achievements are backed by

data that is independently verified.

Steve Denton | HSE Manager

36


4.0 Independent Verification

Key independent verification achievements

2005

Lloyds LRQA

Independently assess Fosters

new ISO14001 and existing

ISO9001 accreditation

2009

The Carbon Trust

Independently measured our

carbon footprint reductions

to award us their standard

2008

Certified Safety Culture

Fosters commitment to safe

working practices for its employees

and customers is independently

accredited by SAFE

2011

Product Testing

RD&T independent test body

ex Bristol University verified

all Foster ultra low energy

performance data for the

new G2 range

37


Corporate Social Responsibility Report 2013

BREEAM

BREEAM (Building Research Establishment

Environmental Assessment Method) is the world's

foremost environmental assessment method and

rating system for buildings.

BREEAM sets the standard for best practice in sustainable building design, construction

and operation and has become one of the most comprehensive and widely recognised

measures of a building's environmental performance.

A BREEAM assessment uses recognised

measures of performance, which are

set against established benchmarks, to

evaluate a building’s specification, design,

construction and use. The measures used

represent a broad range of categories and

criteria from energy to ecology.

They include aspects related to energy

and water use, the internal environment

(health and well-being), pollution,

transport, materials, waste, ecology and

management processes.

Foster has a technical sales engineer

trained to BREEAM standard who has

been able to assist at early design

stages of projects where refrigeration

makes a significant contribution to the

environmental impact of the building.

For example; New Cross Hospital Central

Processing Unit (CPU) pictured right ,

where Foster’s low energy equipment

design contributed to BREEAM points for

the overall buildings assessment.

“Refrigeration sustainably designed

can make a significant contribution

to a project’s BREEAM rating”

Andrew Galeckyj | Project Business Manager

38


4.0 Independent Verification

A selection of our awards

39


Corporate Social Responsibility Report 2013

Summary of achievements and future plans

Climate Change

On Going Complete

Develop G2 range of ultra low energy cabinets

Expand range of low energy products

Green maintenance packages

Zero gas leak strategy on cabinet products

Growth in number of customers buying hydrocarbon products

PRODUCT

Expand innovative testing programme to non core product

Develop more thermally efficient cabinets

Cyclopentane foam insulation to reduce waste & save energy

Temperature monitoring capability

Smart storage systems for coldrooms to reduce carbon footprint

Low carbon refrigeration systems for walk in products

Improve thermal efficiency of coldstore construction

Promote and offer our low energy expertise to distributor network

MANUFACTURING

Installation of low energy lighting in all factory plants

Change packaging to save energy

New low energy fibre optic laser cutting equipment

Generate nitrogen on site to reduce carbon emissions

Reduce pallet usage through manufacturing efficiencies

Develop new methods to reduce electric and gas consumption

Reduce carbon emissions by a further 2% each year

Reduce C02 emissions from fleet emissions by 25% of 2009 figures

Research and develop new low energy technologies for our manufacturing site

GENERAL

EUP Directive on energy standards and ensure compliance

Invest in new information technology to save energy

Source parts and materials from local sources wherever possible

Maintain our Carbon Trust Standard

Maintain our ISO14001 Environmental Management Standard

40


3.0 Social Responsibility

Sustainability

On Going Complete

PRODUCT

Develop products that increase longevity and sustainability

Manufacture products that can easily be recycled

Maximise recycling of end of life products

Recycle 100% of our wood waste

MANUFACTURING

Reduce chemical waste in all operations

Use reusable plastic containers on manufacturing line to eliminate packaging

Reduce paper usage

Invest in latest manufacturing equipment

Ensure waste disposal is compliant with new European Waste Framework

Partner and encourage our suppliers in sustainable projects

Investigate the use of solar water heating

GENERAL

Capture and use grey water on site

Biodiversity project for plant perimeter land

Develop BREEAM specifications for sustainable projects

Social Responsibility

On Going Complete

Train and develop our staff in NVQs and other qualifications

Develop our membership of the Ethical Trading Initiative (ETI)

SEDEX auditing partnerships with customers and suppliers

Support and work with local communities and charities

GENERAL

'Green Weeks' and environmental interaction with our stakeholders

Encourage staff to pioneer green projects within the business

Develop environmental champions throughout the business

Maintain and improve our strong Health, Safety and Welfare record

Follow and promote ITWs code of ethics

Develop green papers to inform on sustainable issues

41


Corporate Social Responsibility Report 2013

Working today, protecting

tomorrow steering group

Paul Veried, Vice President Refrigeration

& Weigh Europe

Chris Playford, Market and Development Director

Steve Denton, HSE Manager

Andy Rasberry, Aftersales Manager

Ashley Sword, Sales Director

Dave Sullivan, Manufacturing Director

Steve Ennis, Procurement Manager

Laura Kirk, Head of Marketing

42


About this report

Foster refrigerator has always taken its environmental

responsibilities seriously. This report details our

progress so far on these important aspects of

our business and our ambitions for the future.

Its purpose is to inform our customers, employees,

business partners, suppliers and the local community

who may take an interest in our social, environmental

and ethical performance.

Since 2008 Foster’s working today,

protecting tomorrow steering group has

focussed on the wide range of social,

environmental and ethical issues which have

an impact on our business either directly

or indirectly. These issues are continually

evolving and the steering group’s role is to

plan and implement progressive initiatives

to ensure the Foster business leads in

developing sustainable business.

> Overview

Our two ISO standards ISO 9001 Quality

Management Standard and ISO14001

Environmental Management Standard

are audited by Lloyds Register Quality

Assurance (LRQA) with 6 monthly

surveillance visits and full reassessments

every three years.

> Audience

A varied audience of stakeholders

have an interest in Foster Refrigerator’s

performance on social, ethical and

environmental issues. Our audience

includes our dealer network, key account

customers, specifiers, food service

consultants, independent owners, public

bodies and organisations, suppliers,

staff and shareholders. We’ve included

content that contains specialist details

for those looking for a more in-depth

understanding and more general themes

for those seeking broader information.

> Report Structure

We have marked out the main report

under the headings of Climate Change,

Sustainability, Social Responsibility and

Independent Verification. In future

reports we will provide a process update

on the information under these headings

and the objectives we have outlined in

the Foster action plan.

> Data

The data and statements contained in

this report range from 2009 to 2012.

We have used the most recent data

where available.

> Assurance

The content of this report has been

provided and concluded by Foster

Refrigerator’s working today protecting

tomorrow steering group. All data

such as energy, gas, water and delivery

transport has been provided by suppliers

and assessed by Foster.

All other data is provided in accordance

with the requirements of ISO14001 and

the Carbon Trust Standard. The steering

groups assess the targets in this report as

part of an on-going comprehensive review

process and our commitment to improve

our environmental performance ahead of

the requirements of future legislation.

43


A Division of ITW Ltd

Foster Refrigerator

Oldmedow Road

King’s Lynn

Norfolk PE30 4JU

United Kingdom

To find out more:

Call: +44 (0)843 216 8800

Fax: +44 (0)843 216 4700

Email: sales@foster-uk.com

Visit: fosterrefrigerator.co.uk

ISO 9001 ISO 14001

Literature Code: CSR2.03.13

We reserve the right to change specifications without notice.

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